U.S. patent number 10,668,567 [Application Number 15/933,160] was granted by the patent office on 2020-06-02 for multi-operation laser tooling for deposition and material processing operations.
This patent grant is currently assigned to nLIGHT, Inc.. The grantee listed for this patent is nLIGHT, Inc.. Invention is credited to Aaron W. Brown, Ken Gross, Dahv A. V. Kliner, Brian M. Victor.
![](/patent/grant/10668567/US10668567-20200602-D00000.png)
![](/patent/grant/10668567/US10668567-20200602-D00001.png)
![](/patent/grant/10668567/US10668567-20200602-D00002.png)
![](/patent/grant/10668567/US10668567-20200602-D00003.png)
![](/patent/grant/10668567/US10668567-20200602-D00004.png)
![](/patent/grant/10668567/US10668567-20200602-D00005.png)
![](/patent/grant/10668567/US10668567-20200602-D00006.png)
![](/patent/grant/10668567/US10668567-20200602-D00007.png)
![](/patent/grant/10668567/US10668567-20200602-D00008.png)
![](/patent/grant/10668567/US10668567-20200602-D00009.png)
![](/patent/grant/10668567/US10668567-20200602-D00010.png)
View All Diagrams
United States Patent |
10,668,567 |
Victor , et al. |
June 2, 2020 |
Multi-operation laser tooling for deposition and material
processing operations
Abstract
Disclosed herein are methods, apparatus, and systems for a
multi-operation optical beam delivery device having a laser source
to generate the optical beam. A beam characteristic conditioner
that, in response to a control input indicating a change between
the different laser process operations, controllably modifies the
beam characteristics for a corresponding laser process operation of
the different laser process operations. A delivery fiber has an
input end coupled to the beam characteristic conditioner and an
output end coupled to a process head for performing the
corresponding laser process operation.
Inventors: |
Victor; Brian M. (Camas,
WA), Gross; Ken (Vancouver, WA), Brown; Aaron W.
(Vancouver, WA), Kliner; Dahv A. V. (Portland, OR) |
Applicant: |
Name |
City |
State |
Country |
Type |
nLIGHT, Inc. |
Vancouver |
WA |
US |
|
|
Assignee: |
nLIGHT, Inc. (Vancouver,
WA)
|
Family
ID: |
62977446 |
Appl.
No.: |
15/933,160 |
Filed: |
March 22, 2018 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20180214985 A1 |
Aug 2, 2018 |
|
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
15607399 |
May 26, 2017 |
10423015 |
|
|
|
15607410 |
May 26, 2017 |
|
|
|
|
15607411 |
May 26, 2017 |
10295845 |
|
|
|
PCT/US2017/034848 |
May 26, 2017 |
|
|
|
|
62401650 |
Sep 29, 2016 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G02B
6/262 (20130101); B23K 26/06 (20130101); B29C
64/371 (20170801); G02B 27/0994 (20130101); B29C
64/268 (20170801); G02B 6/14 (20130101); B23K
26/043 (20130101); B28B 1/001 (20130101); B29C
64/153 (20170801); B23K 26/342 (20151001); B29C
64/141 (20170801); B23K 26/1464 (20130101); B23K
26/123 (20130101); G02B 27/0927 (20130101); G02B
6/03627 (20130101); G02B 6/03688 (20130101); G02B
6/0365 (20130101); G02B 6/03611 (20130101); G02B
6/03638 (20130101); G02B 6/03633 (20130101); G02B
6/0281 (20130101); B22F 3/1055 (20130101); B33Y
40/00 (20141201); G02B 6/03666 (20130101); B33Y
30/00 (20141201); B22F 2003/1056 (20130101) |
Current International
Class: |
B23K
26/34 (20140101); G02B 27/09 (20060101); G02B
6/14 (20060101); B29C 64/371 (20170101); B29C
64/268 (20170101); B29C 64/141 (20170101); B28B
1/00 (20060101); B23K 26/342 (20140101); G02B
6/26 (20060101); B23K 26/04 (20140101); B23K
26/06 (20140101); B29C 64/153 (20170101); B23K
26/14 (20140101); B23K 26/12 (20140101); B33Y
30/00 (20150101); G02B 6/028 (20060101); B33Y
40/00 (20200101); G02B 6/036 (20060101); B22F
3/105 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
101907742 |
|
Dec 2010 |
|
CN |
|
101907742 |
|
Jul 2012 |
|
CN |
|
H11287922 |
|
Oct 1999 |
|
JP |
|
H11344636 |
|
Dec 1999 |
|
JP |
|
2005070608 |
|
Mar 2005 |
|
JP |
|
2016201558 |
|
Dec 2016 |
|
JP |
|
2012165389 |
|
Dec 2012 |
|
WO |
|
2016061657 |
|
Apr 2016 |
|
WO |
|
Other References
Bergmann et al., Effects of diode laser superposition on pulsed
laser welding of Aluminum, Lasers in Manufacturing Conference 2013,
Physics Procedia 41 ( 2013 ) 180-189 (Year: 2013). cited by
examiner .
CAILabs, Canuda, Application Note, 2015 (Year: 2015). cited by
examiner .
CAILabs, Canuda, Application note, Flexible high-power laser beam
shaping (Year: 2015). cited by examiner .
J. M. Daniel, J. S. Chan, J. W. Kim, M. Ibsen, J. Sahu, and W. A.
Clarkson, "Novel Technique for Mode Selection in a Large-Mode-Area
Fiber Laser," in Conference on Lasers and Electro-Optics 2010, OSA
Technical Digest (CD) (Optical Society of America, 2010), paper
CWC5 (Year: 2010). cited by examiner .
J. M. O. Daniel, J. S. P. Chan, J. W. Kim, J. K. Sahu, M. Ibsen,
and W. A. Clarkson, "Novel technique for mode selection in a
multimode fiber laser," Opt. Express 19, 12434-12439 (2011) (Year:
2011). cited by examiner .
Faidel et al., Improvement of selective laser melting by beam
shaping and minimized thermally induced effects in optical systems,
9th International Conference on Photonic Technologies LANE 2016
(Year: 2016). cited by examiner .
John M. Fini, "Bend-compensated design of large-mode-area fibers,"
Opt. Lett. 31, 1963-1965 (2006) (Year: 2006). cited by examiner
.
John M. Fini and Jeffrey W. Nicholson, "Bend compensated
large-mode-area fibers: achieving robust single-modedness with
transformation optics," Opt. Express 21, 19173-19179 (2013) (Year:
2013). cited by examiner .
John M. Fini, "Large mode area fibers with asymmetric bend
compensation," Opt. Express 19, 21866-21873 (2011) (Year: 2011).
cited by examiner .
Garcia et al., Fast adaptive laser shaping based on multiple laser
incoherent combining, Proc. SPIE 10097, High-Power Laser Materials
Processing: Applications, Diagnostics, and Systems VI, 1009705
(Feb. 22, 2017); doi: 10.1117/12.2250303 (Year: 2017). cited by
examiner .
Huang et al., "All-fiber mode-group-selective photonic lantern
using graded-index multimode fibers," Opt. Express 23, 224-234
(2015) (Year: 2015). cited by examiner .
Jain et al., "Multi-Element Fiber Technology for Space-Division
Multiplexing Applications," Opt. Express 22, 3787-3796 (2014)
(Year: 2014). cited by examiner .
Jin et al., "Mode Coupling Effects in Ring-Core Fibers for
Space-Division Multiplexing Systems," in Journal of Lightwave
Technology, vol. 34, No. 14, pp. 3365-3372, Jul. 15, 15, 2016. doi:
10.1109/JLT.2016.2564991 (Year: 2016). cited by examiner .
King et al., Observation of keyhole-mode laser melting in laser
powder-bed fusion additive manufacturing, Journal of Materials
Processing Technology 214 (2014) 2915-2925 (Year: 2014). cited by
examiner .
D. A. V. Kliner, "Novel, High-Brightness, Fibre Laser Platform for
kW Materials Processing Applications," in 2015 European Conference
on Lasers and Electro-Optics--European Quantum Electronics
Conference, (Optical Society of America, 2015), paper CJ_11_2.
(Year: 2015). cited by examiner .
Kliner D.A.V., Bambha R.P., Do B.T., Farrow R.L., Feve J.-P., Fox
B.P., Hadley G.R., Wien G., Overview of Sandia's fiber laser
program (2008) Proceedings of SPIE--The International Society for
Optical Engineering, 6952 , art. No. 695202 (Year: 2008). cited by
examiner .
Koplow et al., "Single-mode operation of a coiled multimode fiber
amplifier," Opt. Lett. 25, 442-444 (2000) (Year: 2000). cited by
examiner .
Laskin, Applying of refractive spatial beam shapers with scanning
optics ICALEO, 941-947 (2011) (Year: 2011). cited by examiner .
Longhi et al., Self-focusing and nonlinear periodic beams in
parabolic index optical fibres, Published May 4, 2004 o IOP
Publishing Ltd Journal of Optics B: Quantum and Semiclassical
Optics, vol. 6, No. 5 (Year: 2004). cited by examiner .
Mumtaz et al., Selective Laser Melting of thin wall parts using
pulse shaping, Journal of Materials Processing Technology 210
(2010) 279-287 (Year: 2010). cited by examiner .
Putsch et al., Active optical system for laser structuring of 3D
surfaces by remelting, Proc. SPIE 8843, Laser Beam Shaping XIV,
88430D (Sep. 28, 2013); doi: 10.1117/12.2023306
https://www.osapublishing.org/conference.cfm?meetingid=90&yr=2015
(Year: 2013). cited by examiner .
Sandia National Laboratories--Brochure (POC--D.A.V. Kliner);
"Mode-Filtered Fiber Amplifier," 2007 (Year: 2007). cited by
examiner .
SeGall et al., "Simultaneous laser mode conversion and beam
combining using multiplexed volume phase elements," in Advanced
Solid-State Lasers Congress, G. Huber and P. Moulton, eds., OSA
Technical Digest (online) (Optical Society of America, 2013), paper
AW2A.9. (Year: 2013). cited by examiner .
Thiel et al., Reliable Beam Positioning for Metal-based Additive
Manufacturing by Means of Focal Shift Reduction, Lasers in
Manufacturing Conference 2015. (Year: 2015). cited by examiner
.
Van Newkirk et al., "Bending sensor combining multicore fiber with
a mode-selective photonic lantern," Opt. Lett. 40, 5188-5191 (2015)
(Year: 2015). cited by examiner .
Wischeropp et al., Simulation of the effect of different laser beam
intensity profiles on heat distribution in selective laser melting,
Lasers in Manufacturing Conference 2015. (Year: 2015). cited by
examiner .
Xiao et al., "Fiber coupler for mode selection and high-efficiency
pump coupling," Opt. Lett. 38, 1170-1172 (2013) (Year: 2013). cited
by examiner .
Ye et al., Mold-free fs laser shock micro forming and its plastic
deformation mechanism, Optics and Lasers in Engineering 67 (2015)
74-82. (Year: 2015). cited by examiner .
Yu et al., Laser material processing based on non-conventional beam
focusing strategies, 9th International Conference on Photonic
Technologies LANE 2016 (Year: 2016). cited by examiner .
Zhirnov et al., Laser beam profiling: experimental study of its
influence on single-track formation by selective laser melting,
Mechanics & Industry 16, 709 (2015) (Year: 2015). cited by
examiner .
Keicher et al., Advancing 3D Printing of Metals and Electronics
using Computational Fluid Dynamics
https://www.osti.gov/servlets/purl/1324235; "Keicher" (Year: 2015).
cited by examiner .
Balazic, Matej, Additive Manufacturing and 3D Printing LENS
Technology,
http://www.lortek.es/files/fab-aditiva/efesto-ik4-lortek-27th-november-20-
13.pdf (Year: 2013). cited by examiner .
Jollivet, Clemence, Specialty Fiber Lasers and Novel Fiber Devices,
Doctoral Dissertation, University of Central Florida, 2014 (Year:
2014). cited by examiner .
Jollivet et al., Advances in Multi-Core Fiber Lasers, Invited
Presentation, DOI: 10.1364/LAOP.2014.LM1D.3.,2014 (Year: 2014).
cited by examiner .
Kosolapov et al., Hollow-core revolver fibre with a
double-capillary reflective cladding, Quantum Electron. 46 267
(Year: 2016). cited by examiner .
Messerly, et al., Field-flattened, ring-like propagation modes,
Optics Express, V. 21, N. 10, p. 12683 (Year: 2013). cited by
examiner .
Messerly et al., Patterned flattened modes, Optics Letters, V. 38,
N. 17, p. 3329 (Year: 2013). cited by examiner .
Salceda-Delgado et al., Compact fiber-optic curvature sensor based
on super-mode interference in a seven-core fiber, Optics Letters,
V. 40, N. 7, p. 1468, (Year: 2015). cited by examiner .
Zhang et al., Switchable multiwavelength fiber laser by using a
compact in-fiber Mach-Zehnder interferometer, J. Opt. 14 (2012
(045403) (Year: 2012). cited by examiner .
I.V. Zlodeev and O.V. Ivanov, Transmission spectra of a double-clad
fibre structure under bending, Quantum Electronics 43 (6) 535-541
(2013) (Year: 2013). cited by examiner .
Tam et al., An imaging fiber-based optical tweezer array for
microparticle array assembly, Appl. Phys. Lett. 84, 4289 (2004);
https://doi.org/10.1063/1.1753062 (Year: 2004). cited by examiner
.
International Search Report and Written Opinion for International
Application No. PCT/US2018/023944, dated Aug. 2, 2018, 7 pages.
cited by applicant.
|
Primary Examiner: Radkowski; Peter
Parent Case Text
RELATED APPLICATIONS
This application is a continuation-in-part of each of the following
applications filed May 26, 2017: U.S. patent application Ser. Nos.
15/607,399; 15/607,410; and 15/607,411; and International
Application No. PCT/US2017/034848. Each of these applications
claims benefit of U.S. Provisional Patent Application No.
62/401,650, filed Sep. 29, 2016. All of these applications are
incorporated by reference herein in their entireties.
Claims
The invention claimed is:
1. A multi-operation optical beam delivery device to facilitate
different laser process operations by modification of beam
characteristics of an optical beam, the different laser process
operations including laser deposition and processing of a
deposition region, the multi-operation optical beam delivery device
comprising: a laser source to generate the optical beam; a beam
characteristic conditioner that, in response to a control input
indicating a change between the different laser process operations,
controllably modifies the beam characteristics for a corresponding
laser process operation of the different laser process operations,
the beam characteristic conditioner including first and second
lengths of fiber having, respectively, first and second refractive
index profiles (RIPs), the first RIP enabling, in response to an
applied perturbation, modification of the beam characteristics to
form an adjusted optical beam having modified beam characteristics,
and the second RIP defined by multiple confinement regions formed
to confine, and situated to receive through a fiber-coupling
interface functionally directly coupling the first and second
lengths of fiber, at least a portion of the adjusted optical beam
within at least one of the multiple confinement regions; and a
delivery fiber having an input end coupled to the beam
characteristic conditioner and an output end coupled to a process
head for performing the corresponding laser process operation.
2. The multi-operation optical beam delivery device of claim 1, in
which the beam characteristic conditioner includes: a first length
of fiber through which the optical beam propagates and which has a
first refractive index profile (RIP), the first RIP enabling, in
response to an applied perturbation, modification of the beam
characteristics to form an adjusted optical beam having modified
beam characteristics; and a second length of fiber coupled to the
first length of fiber and having multiple confinement regions
defining a second RIP that is different from the first RIP, the
multiple confinement regions arranged to confine at least a portion
of the adjusted optical beam and generate from it, at an output of
the second length of fiber, an adjustable spatial or angular
distribution that, in response to the applied perturbation, changes
for facilitating the corresponding laser process operation.
3. The multi-operation optical beam delivery device of claim 1, in
which the beam characteristics define spatial and angular
distributions, and in which the beam characteristic conditioner is
configured to modify the angular distribution by a desired amount
that is non-reciprocal to an amount of change in the spatial
distribution.
4. The multi-operation optical beam delivery device of claim 1, in
which the beam characteristics define spatial and angular
distributions, and in which the beam characteristic conditioner is
configured to change the spatial distribution by a desired amount
that is non-reciprocal to an amount of change in the angular
distribution.
5. The multi-operation optical beam delivery device of claim 1,
further comprising the process head having optical components
arranged in a fixed optical configuration.
6. The multi-operation optical beam delivery device of claim 1,
further comprising the process head having optical components
arranged in a variable optical configuration.
7. The multi-operation optical beam delivery device of claim 1, in
which the processing of the deposition region includes one or more
of addition of a secondary feature onto a previously deposited
primary feature, thermal treatment of workpiece material or
material deposited thereon, and removal of workpiece material or
material deposited thereon.
8. The multi-operation optical beam delivery device of claim 1, in
which the processing of the deposition region includes
pre-processing of workpiece material or material deposited
thereon.
9. The multi-operation optical beam delivery device of claim 1, in
which the processing of the deposition region includes
post-processing of workpiece material or material deposited
thereon.
10. The multi-operation optical beam delivery device of claim 1,
further comprising a multi-operation deposition nozzle having
multiple orifices configured to deliver different deposition
materials, the different deposition materials including a first
material and a second material, the first material for delivery
during a first laser process operation and the second material for
delivery during a second laser process operation that is different
from the first laser process operation.
11. The multi-operation optical beam delivery device of claim 10,
in which the different deposition materials include deposition
media.
12. The multi-operation optical beam delivery device of claim 11,
in which the deposition media includes one or more of wire, rod,
strip, sheet, powder, and slurry deposition media.
13. The multi-operation optical beam delivery device of claim 10,
in which the different deposition materials include a gas.
14. The multi-operation optical beam delivery device of claim 13,
in which the gas includes one or more of inert, active, oxidizing,
and nitriding gas.
15. The multi-operation optical beam delivery device of claim 13,
in which the gas modifies material chemistry or assists in delivery
of deposition media.
16. The multi-operation optical beam delivery device of claim 10,
in which the multiple orifices include first and second orifices
that are concentrically arranged in the multi-operation deposition
nozzle.
17. The multi-operation optical beam delivery device of claim 10,
in which the multiple orifices include first and second orifices
that are mutually azimuthally spaced apart.
18. The multi-operation optical beam delivery device of claim 10,
further comprising a controller to produce the control input and
coordinate the change between the different laser process
operations with delivery of deposition materials associated with
the corresponding laser process operation.
19. The multi-operation optical beam delivery device of claim 1, in
which the corresponding laser process operation includes deposition
of media on one or more of metals, metal alloys, polymers,
ceramics, and combinations thereof.
20. The multi-operation optical beam delivery device of claim 1, in
which the beam characteristics define spatial and angular
distributions, and in which the beam characteristic conditioner is
configured to selectively change the spatial distribution
substantially independently from the angular distribution, the
angular distribution substantially independently from the spatial
distribution, or both the spatial and angular distributions in a
non-reciprocal manner to each other.
21. The multi-operation optical beam delivery device of claim 1, in
which the first RIP is a waveguide configured to impart transverse
displacement to the optical beam in response to the applied
perturbation.
22. The multi-operation optical beam delivery device of claim 1, in
which the first length of fiber includes an input for receiving the
optical beam from an input fiber.
23. The multi-operation optical beam delivery device of claim 22,
in which the first length of fiber includes an output fused to an
input of the second length of fiber.
24. The multi-operation optical beam delivery device of claim 1, in
which the fiber-coupling interface includes an index-matching
material.
25. The multi-operation optical beam delivery device of claim 1, in
which the fiber-coupling interface includes a splice.
26. The multi-operation optical beam delivery device of claim 1, in
which the fiber-coupling interface includes a fiber joint.
27. The multi-operation optical beam delivery device of claim 1, in
which the fiber-coupling interface includes a connector.
28. The multi-operation optical beam delivery device of claim 1, in
which the fiber-coupling interface maintains a substantially
unaltered operative relationship between the first and second RIPs.
Description
TECHNICAL FIELD
This disclosure generally relates to laser deposition. More
particularly, this disclosure relates to a multi-operation laser
(e.g., one having a controllable spot size, divergence profile,
spatial profile, beam shape, or the like, or any combination
thereof) for achieving multiple laser processing tasks using a
single tool.
BACKGROUND
Deposition of materials (wire, powder, or strip) using lasers is
inherently a process that produces low-tolerance features, or it
may be intentionally low tolerance to increase throughput or
deposition rate at the cost of feature resolution. To further
refine a low tolerance finish or develop other desired features,
further processing of artifacts left over from a previous additive
process is sometimes performed during subsequent removal,
smoothing, refining, ablation, or machining operations. Such
subsequent processing operations have sometimes used a separate
machine to perform material removal by methods involving mechanical
post-processing, chemical treatment, or thermal treatment (e.g., by
application of heat). Separate machines for such operations can
add, among other things, production delay, tooling cost, and
training burden.
Patent Application Pub. No. US 2009/0283501 A1 of Erikson et al.
describes a laser deposition apparatus for preheating a workpiece
prior to deposition. The cross-sectional width of a beam is
increased and decreased for, respectively, preheating and
deposition by moving optical components housed in a deposition
nozzle--close to the operating environment and potentially
susceptible to debris, among other deficiencies.
SUMMARY
The present inventors have recognized that performing additional
laser processing with the same laser tool used for laser-assisted
deposition (or simply, deposition) enhances speed and efficiency.
Accordingly, in some embodiments, a laser source and beam
characteristic conditioner spaced apart from a process head may be
used to deliver adjustable beams tailored for different processing
operations. Furthermore, a multi-operation optical beam delivery
device described herein includes a means by which to largely (i.e.,
subject to practical physical and implementation-specific
limitations) decouple spatial and angular distributions so that
they are not constrained by a reciprocal relationship.
A multi-operation optical beam delivery device facilitates
different laser process operations by modification of beam
characteristics of an optical beam. The different laser process
operations includes laser deposition and processing of a deposition
region. The device has a laser source to generate the optical beam,
a beam characteristic conditioner, and a delivery fiber. The beam
characteristic conditioner, in response to a control input
indicating a change between the different laser process operations,
controllably modifies the beam characteristics for a corresponding
laser process operation of the different laser process operations.
The delivery fiber has an input end coupled to the beam
characteristic conditioner and an output end coupled to a process
head for performing the corresponding laser process operation.
In some embodiments, the beam characteristic conditioner has first
and second lengths of fiber. The first length, through which the
optical beam propagates, has a first refractive index profile
(RIP). The first RIP enables, in response to an applied
perturbation, modification of the beam characteristics to form an
adjusted optical beam having modified beam characteristics. The
second length of fiber is coupled to the first length of fiber and
has multiple confinement regions defining a second RIP that is
different from the first RIP. The multiple confinement regions are
arranged to confine at least a portion of the adjusted optical beam
and generate from it, at an output of the second length of fiber,
an adjustable spatial or angular distribution that, in response to
the applied perturbation, changes for facilitating the
corresponding laser process operation.
Some advantages of using a beam characteristic conditioner over
free-space optics are simplification of the process head; reduction
in size and weight of the process head; ease of use, installation,
and maintenance (e.g., no free-space optics to keep clean); beam
characteristics are consistent along an entire propagation path
defined by the feed fiber; and alignment issues between of the
free-space optics of the process head are avoided. Additional
aspects and advantages will be apparent from the following detailed
description of preferred embodiments, which proceeds with reference
to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, wherein like reference numerals
represent like elements, are incorporated in and constitute a part
of this specification and, together with the description, explain
the advantages and principles of the presently disclosed
technology. In the drawings,
FIG. 1 illustrates an example fiber structure for providing a laser
beam having variable beam characteristics;
FIG. 2 depicts a cross-sectional view of an example fiber structure
for delivering a beam with variable beam characteristics;
FIG. 3 illustrates an example method of perturbing a fiber
structure for providing a beam having variable beam
characteristics;
FIG. 4 is a graph illustrating the calculated spatial profile of
the lowest-order mode (LP.sub.01) for a first length of a fiber for
different fiber bend radii;
FIG. 5 illustrates an example of a two-dimensional intensity
distribution at a junction when a fiber for varying beam
characteristics is nearly straight;
FIG. 6 illustrates an example of a two-dimensional intensity
distribution at a junction when a fiber for varying beam
characteristics is bent with a radius chosen to preferentially
excite a particular confinement region of a second length of
fiber;
FIGS. 7-10 depict experimental results to illustrate further output
beams for various bend radii of a fiber for varying beam
characteristics shown in FIG. 2;
FIGS. 11-16 illustrate cross-sectional views of example first
lengths of fiber for enabling adjustment of beam characteristics in
a fiber assembly;
FIGS. 17-19 illustrate cross-sectional views of example second
lengths of fiber ("confinement fibers") for confining adjusted beam
characteristics in a fiber assembly;
FIGS. 20 and 21 illustrate cross-sectional views of example second
lengths of fiber for changing a divergence angle of and confining
an adjusted beam in a fiber assembly configured to provide variable
beam characteristics;
FIG. 22A illustrates an example laser system including a fiber
assembly configured to provide variable beam characteristics
disposed between a feeding fiber and process head;
FIG. 22B illustrates an example a laser system including a fiber
assembly configured to provide variable beam characteristics
disposed between a feeding fiber and process head;
FIG. 23 illustrates an example laser system including a fiber
assembly configured to provide variable beam characteristics
disposed between a feeding fiber and multiple process fibers;
FIG. 24 illustrates examples of various perturbation assemblies for
providing variable beam characteristics according to various
examples provided herein;
FIG. 25 illustrates an example process for adjusting and
maintaining modified characteristics of an optical beam;
FIGS. 26-28 are cross-sectional views illustrating example second
lengths of fiber ("confinement fibers") for confining adjusted beam
characteristics in a fiber assembly;
FIG. 29 is a block diagram of a multi-operation optical beam
delivery device, according to one embodiment;
FIG. 30 is a block diagram of a multi-operation optical beam
delivery device, according to another embodiment showing a
supplemental optional zoom optic and a series of three
single-purpose nozzles;
FIG. 31 is a cross-sectional view, taken along lines 31-31 of FIG.
29, showing a multi-operation nozzle, according to one
embodiment;
FIG. 32 is a sectional view, taken along lines 32-32 of FIG. 29,
showing the multi-operation nozzle; and
FIG. 33 is a bottom plan view of a multi-operation nozzle,
according to another embodiment.
DETAILED DESCRIPTION
As used herein throughout this disclosure and in the claims, the
singular forms "a," "an," and "the" include the plural forms unless
the context clearly dictates otherwise. Additionally, the term
"includes" means "comprises." Further, the term "coupled" does not
exclude the presence of intermediate elements between the coupled
items. Also, the terms "modify" and "adjust" are used
interchangeably to mean "alter."
The systems, apparatus, and methods described herein should not be
construed as limiting in any way. Instead, the present disclosure
is directed toward all novel and non-obvious features and aspects
of the various disclosed embodiments, alone and in various
combinations and sub-combinations with one another. The disclosed
systems, methods, and apparatus are not limited to any specific
aspect or feature or combinations thereof, nor do the disclosed
systems, methods, and apparatus require that any one or more
specific advantages be present or problems be solved. Any theories
of operation are to facilitate explanation, but the disclosed
systems, methods, and apparatus are not limited to such theories of
operation.
Although the operations of some of the disclosed methods are
described in a particular sequential order for convenient
presentation, it should be understood that this manner of
description encompasses rearrangement, unless a particular ordering
is required by specific language set forth below. For example,
operations described sequentially may in some cases be rearranged
or performed concurrently. Moreover, for the sake of simplicity,
the attached figures may not show the various ways in which the
disclosed systems, methods, and apparatus can be used in
conjunction with other systems, methods, and apparatus.
Additionally, the description sometimes uses terms like "produce"
and "provide" to describe the disclosed methods. These terms are
high-level abstractions of the actual operations that are
performed. The actual operations that correspond to these terms
will vary depending on the particular implementation and are
readily discernible by one of ordinary skill in the art.
In some examples, values, procedures, or apparatus are referred to
as "lowest," "best," "minimum," or the like. It will be appreciated
that such descriptions are intended to indicate that a selection
among many used functional alternatives can be made, and such
selections need not be better, smaller, or otherwise preferable to
other selections. Examples are described with reference to
directions indicated as "above," "below," "upper," "lower," and the
like. These terms are used for convenient description, but do not
imply any particular spatial orientation.
Definitions
Definitions of words and terms as used herein: 1. The term "beam
characteristics" refers to one or more of the following terms used
to describe an optical beam. In general, the beam characteristics
of most interest depend on the specifics of the application or
optical system. 2. The term "beam diameter" is defined as the
distance across the center of the beam along an axis for which the
irradiance (intensity) equals 1/e.sup.2 of the maximum irradiance.
While examples disclosed herein generally use beams that propagate
in azimuthally symmetric modes, elliptical or other beam shapes can
be used, and beam diameter can be different along different axes.
Circular beams are characterized by a single beam diameter. Other
beam shapes can have different beam diameters along different axes.
3. The term "spot size" is the radial distance (radius) from the
center point of maximum irradiance to the 1/e.sup.2 point. 4. The
term "beam divergence distribution" is the power vs the full cone
angle. This quantity is sometimes called the "angular distribution"
or "NA distribution." 5. The term "beam parameter product" (BPP) of
a laser beam is defined as the product of the beam radius (measured
at the beam waist) and the beam divergence half-angle (measured in
the far field). The units of BPP are typically mm-mrad. 6. A
"confinement fiber" is defined to be a fiber that possesses one or
more confinement regions, wherein a confinement region comprises a
higher-index region (core region) surrounded by a lower-index
region (cladding region). The RIP of a confinement fiber may
include one or more higher-index regions (core regions) surrounded
by lower-index regions (cladding regions), wherein light is guided
in the higher-index regions. Each confinement region and each
cladding region can have any RIP, including but not limited to
step-index and graded-index. The confinement regions may or may not
be concentric and may be a variety of shapes such as circular,
annular, polygonal, arcuate, elliptical, or irregular, or the like
or any combination thereof. The confinement regions in a particular
confinement fiber may all have the same shape or may be different
shapes. Moreover, confinement regions may be co-axial or may have
offset axes with respect to one another. Confinement regions may be
of uniform thickness about a central axis in the longitudinal
direction, or the thicknesses may vary about the central axis in
the longitudinal direction. 7. The term "intensity distribution"
refers to optical intensity as a function of position along a line
(1D profile) or on a plane (2D profile). The line or plane is
usually taken perpendicular to the propagation direction of the
light. It is a quantitative property. 8. "Luminance" is a
photometric measure of the luminous intensity per unit area of
light travelling in a given direction. 9. "M.sup.2 factor" (also
called "beam quality factor" or "beam propagation factor") is a
dimensionless parameter for quantifying the beam quality of laser
beams, with M.sup.2=1 being a diffraction-limited beam, and larger
M.sup.2 values corresponding to lower beam quality. M.sup.2 is
equal to the BPP divided by .lamda./.pi., where .lamda. is the
wavelength of the beam in microns (if BPP is expressed in units of
mm-mrad). 10. The term "numerical aperture" or "NA" of an optical
system is a dimensionless number that characterizes the range of
angles over which the system can accept or emit light. 11. The term
"optical intensity" is not an official (SI) unit, but is used to
denote incident power per unit area on a surface or passing through
a plane. 12. The term "power density" refers to optical power per
unit area, although this is also referred to as "optical
intensity." 13. The term "radial beam position" refers to the
position of a beam in a fiber measured with respect to the center
of the fiber core in a direction perpendicular to the fiber axis.
14. "Radiance" is the radiation emitted per unit solid angle in a
given direction by a unit area of an optical source (e.g., a
laser). Radiance may be altered by changing the beam intensity
distribution and/or beam divergence profile or distribution. The
ability to vary the radiance profile of a laser beam implies the
ability to vary the BPP. 15. The term "refractive-index profile" or
"RIP" refers to the refractive index as a function of position
along a line (1D) or in a plane (2D) perpendicular to the fiber
axis. Many fibers are azimuthally symmetric, in which case the 1D
RIP is identical for any azimuthal angle. 16. A "step-index fiber"
has a RIP that is flat (refractive index independent of position)
within the fiber core. 17. A "graded-index fiber" has a RIP in
which the refractive index decreases with increasing radial
position (i.e., with increasing distance from the center of the
fiber core). 18. A "parabolic-index fiber" is a specific case of a
graded-index fiber in which the refractive index decreases
quadratically with increasing distance from the center of the fiber
core. Fiber for Varying Beam Characteristics
Disclosed herein are methods, systems, and apparatus configured to
provide a fiber operable to provide a laser beam having variable
beam characteristics (VBC) that may reduce cost, complexity,
optical loss, or other drawbacks of the conventional methods
described above. This VBC fiber is configured to vary a wide
variety of optical beam characteristics. Such beam characteristics
can be controlled using the VBC fiber thus allowing users to tune
various beam characteristics to suit the particular requirements of
an extensive variety of laser processing applications. For example,
a VBC fiber may be used to tune beam diameter, beam divergence
distribution, BPP, intensity distribution, M.sup.2 factor, NA,
optical intensity, power density, radial beam position, radiance,
spot size, or the like, or any combination thereof.
In general, the disclosed technology entails coupling a laser beam
into a fiber in which the characteristics of the laser beam in the
fiber can be adjusted by perturbing the laser beam and/or
perturbing a first length of fiber by any of a variety of methods
(e.g., bending the fiber or introducing one or more other
perturbations) and fully or partially maintaining adjusted beam
characteristics in a second length of fiber. The second length of
fiber is specially configured to maintain and/or further modify the
adjusted beam characteristics. In some cases, the second length of
fiber preserves the adjusted beam characteristics through delivery
of the laser beam to its ultimate use (e.g., materials processing).
The first and second lengths of fiber may comprise the same or
different fibers.
The disclosed technology is compatible with fiber lasers and
fiber-coupled lasers. Fiber-coupled lasers typically deliver an
output via a delivery fiber having a step-index refractive index
profile (RIP), i.e., a flat or constant refractive index within the
fiber core. In reality, the RIP of the delivery fiber may not be
perfectly flat, depending on the design of the fiber. Important
parameters are the fiber core diameter (d.sub.core) and NA. The
core diameter is typically in the range of 10-1000 microns
(although other values are possible), and the NA is typically in
the range of 0.06-0.22 (although other values are possible). A
delivery fiber from the laser may be routed directly to the process
head or workpiece, or it may be routed to a fiber-to-fiber coupler
(FFC) or fiber-to-fiber switch (FFS), which couples the light from
the delivery fiber into a process fiber that transmits the beam to
the process head or the workpiece.
Most materials processing tools, especially those at high power
(>1 kW), employ multimode (MM) fiber, but some employ
single-mode (SM) fiber, which is at the lower end of the d.sub.core
and NA ranges. The beam characteristics from a SM fiber are
uniquely determined by the fiber parameters. The beam
characteristics from a MM fiber, however, can vary (unit-to-unit
and/or as a function of laser power and time), depending on the
beam characteristics from the laser source(s) coupled into the
fiber, the launching or splicing conditions into the fiber, the
fiber RIP, and the static and dynamic geometry of the fiber
(bending, coiling, motion, micro-bending, etc.). For both SM and MM
delivery fibers, the beam characteristics may not be optimum for a
given materials processing task, and it is unlikely to be optimum
for a range of tasks, motivating the desire to be able to
systematically vary the beam characteristics in order to customize
or optimize them for a particular processing task.
In one example, the VBC fiber may have a first length and a second
length and may be configured to be interposed as an in-fiber device
between the delivery fiber and the process head to provide the
desired adjustability of the beam characteristics. To enable
adjustment of the beam, a perturbation device and/or assembly is
disposed in close proximity to and/or coupled with the VBC fiber
and is responsible for perturbing the beam in a first length such
that the beam's characteristics are altered in the first length of
fiber, and the altered characteristics are preserved or further
altered as the beam propagates in the second length of fiber. The
perturbed beam is launched into a second length of the VBC fiber
configured to conserve adjusted beam characteristics. The first and
second lengths of fiber may be the same or different fibers and/or
the second length of fiber may comprise a confinement fiber. The
beam characteristics that are conserved by the second length of VBC
fiber may include any of: beam diameter, beam divergence
distribution, BPP, intensity distribution, luminance, M.sup.2
factor, NA, optical intensity, power density, radial beam position,
radiance, spot size, or the like, or any combination thereof.
FIG. 1 illustrates an example VBC fiber 100 for providing a laser
beam having variable beam characteristics without requiring the use
of free-space optics to change the beam characteristics. VBC fiber
100 comprises a first length of fiber 104 and a second length of
fiber 108. First length of fiber 104 and second length of fiber 108
may be the same or different fibers and may have the same or
different RIPs. The first length of fiber 104 and the second length
of fiber 108 may be joined together by a splice. First length of
fiber 104 and second length of fiber 108 may be coupled in other
ways, may be spaced apart, or may be connected via an interposing
component such as another length of fiber, free-space optics, glue,
index-matching material, or the like or any combination
thereof.
A perturbation device 110 is disposed proximal to and/or envelops a
perturbation region 106. Perturbation device 110 may be a device,
assembly, in-fiber structure, and/or other feature. Perturbation
device 110 at least perturbs optical beam 102 in first length of
fiber 104 or second length of fiber 108 or a combination thereof in
order to adjust one or more beam characteristics of optical beam
102. Adjustment of beam 102 responsive to perturbation by
perturbation device 110 may occur in first length of fiber 104 or
second length of fiber 108 or a combination thereof. Perturbation
region 106 may extend over various widths and may or may not extend
into a portion of second length of fiber 108. As beam 102
propagates in VBC fiber 100, perturbation device 110 may physically
act on VBC fiber 100 to perturb the fiber and adjust the
characteristics of beam 102. Alternatively, perturbation device 110
may act directly on beam 102 to alter its beam characteristics.
Subsequent to being adjusted, perturbed beam 112 has different beam
characteristics from those of beam 102, which will be fully or
partially conserved in second length of fiber 108. In another
example, perturbation device 110 need not be disposed near a
splice. Moreover, a splice may not be needed at all, for example
VBC fiber 100 may be a single fiber, first length of fiber and
second length of fiber could be spaced apart, or secured with a
small gap (air-spaced or filled with an optical material, such as
optical cement or an index-matching material).
Perturbed beam 112 is launched into second length of fiber 108,
where perturbed beam 112 characteristics are largely maintained or
continue to evolve as perturbed beam 112 propagates yielding the
adjusted beam characteristics at the output of second length of
fiber 108. In one example, the new beam characteristics may include
an adjusted intensity distribution. In an example, an altered beam
intensity distribution will be conserved in various structurally
bounded confinement regions of second length of fiber 108. Thus,
the beam intensity distribution may be tuned to a desired beam
intensity distribution optimized for a particular laser processing
task. In general, the intensity distribution of perturbed beam 112
will evolve as it propagates in the second length of fiber 108 to
fill the confinement region(s) into which perturbed beam 112 is
launched responsive to conditions in first length of fiber 104 and
perturbation caused by perturbation device 110. In addition, the
angular distribution may evolve as the beam propagates in the
second fiber, depending on launch conditions and fiber
characteristics. In general, fibers largely preserve the input
divergence distribution, but the distribution can be broadened if
the input divergence distribution is narrow and/or if the fiber has
irregularities or deliberate features that perturb the divergence
distribution. The various confinement regions, perturbations, and
fiber features of second length of fiber 108 are described in
greater detail below. Beams 102 and 112 are conceptual abstractions
intended to illustrate how a beam may propagate through a VBC fiber
100 for providing variable beam characteristics and are not
intended to closely model the behavior of a particular optical
beam.
VBC fiber 100 may be manufactured by a variety of methods including
PCVD (Plasma Chemical Vapor Deposition), OVD (Outside Vapor
Deposition), VAD (Vapor Axial Deposition), MOCVD (Metal-Organic
Chemical Vapor Deposition.) and/or DND (Direct Nanoparticle
Deposition). VBC fiber 100 may comprise a variety of materials. For
example, VBC fiber 100 may comprise SiO.sub.2, SiO.sub.2 doped with
GeO.sub.2, germanosilicate, phosphorus pentoxide, phosphosilicate,
Al.sub.2O.sub.3, aluminosilicate, or the like or any combinations
thereof. Confinement regions may be bounded by cladding doped with
fluorine, boron, or the like or any combinations thereof. Other
dopants may be added to active fibers, including rare-earth ions
such as Er.sup.3+ (erbium), Yb.sup.3+ (ytterbium), Nd.sup.3+
(neodymium), Tm.sup.3+ (thulium), Ho.sup.3+ (holmium), or the like
or any combination thereof. Confinement regions may be bounded by
cladding having a lower index than that of the confinement region
with fluorine or boron doping. Alternatively, VBC fiber 100 may
comprise photonic crystal fibers or micro-structured fibers.
VBC fiber 100 is suitable for use in any of a variety of fiber,
fiber optic, or fiber laser devices, including continuous wave and
pulsed fiber lasers, disk lasers, solid state lasers, or diode
lasers (pulse rate unlimited except by physical constraints).
Furthermore, implementations in a planar waveguide or other types
of waveguides and not just fibers are within the scope of the
claimed technology.
FIG. 2 depicts a cross-sectional view of an example VBC fiber 200
for adjusting beam characteristics of an optical beam. In an
example, VBC fiber 200 may be a process fiber because it may
deliver the beam to a process head for material processing. VBC
fiber 200 comprises a first length of fiber 204 spliced at a
junction 206 to a second length of fiber 208. A perturbation
assembly 210 is disposed proximal to junction 206. Perturbation
assembly 210 may be any of a variety of devices configured to
enable adjustment of the beam characteristics of an optical beam
202 propagating in VBC fiber 200. In an example, perturbation
assembly 210 may be a mandrel and/or another device that may
provide means of varying the bend radius and/or bend length of VBC
fiber 200 near the splice. Other examples of perturbation devices
are discussed below with respect to FIG. 24.
In an example, first length of fiber 204 has a parabolic-index RIP
212 as indicated by the left RIP graph. Most of the intensity
distribution of beam 202 is concentrated in the center of fiber 204
when fiber 204 is straight or nearly straight. Second length of
fiber 208 is a confinement fiber having RIP 214 as shown in the
right RIP graph. Second length of fiber 208 includes confinement
regions 216, 218, and 220. Confinement region 216 is a central core
surrounded by two annular (or ring-shaped) confinement regions 218
and 220. Layers 222 and 224 are structural barriers of lower index
material between confinement regions (216, 218 and 220), commonly
referred to as "cladding" regions. In one example, layers 222 and
224 may comprise rings of fluorosilicate; in some embodiments, the
fluorosilicate cladding layers are relatively thin. Other materials
may be used as well, and claimed subject matter is not limited in
this regard.
In an example, as beam 202 propagates along VBC fiber 200,
perturbation assembly 210 may physically act on fiber 204 and/or
beam 202 to adjust its beam characteristics and generate an
adjusted beam 226. In the current example, the intensity
distribution of beam 202 is modified by perturbation assembly 210.
Subsequent to adjustment of beam 202, the intensity distribution of
adjusted beam 226 may be concentrated in outer confinement regions
218 and 220 with relatively little intensity in the central
confinement region 216. Because each of confinement regions 216,
218, and/or 220 is isolated by the thin layers of lower index
material in barrier layers 222 and 224, second length of fiber 208
can substantially maintain the adjusted intensity distribution of
adjusted beam 226. The beam will typically become distributed
azimuthally within a given confinement region but will not
transition (significantly) between the confinement regions as it
propagates along the second length of fiber 208. Thus, the adjusted
beam characteristics of adjusted beam 226 are largely conserved
within the isolated confinement regions 216, 218, and/or 220. In
some cases, it be may desirable to have the beam 226 power divided
among the confinement regions 216, 218, and/or 220 rather than
concentrated in a single region, and this condition may be achieved
by generating an appropriately adjusted beam 226.
In one example, core confinement region 216 and annular confinement
regions 218 and 220 may be composed of fused silica glass, and
cladding 222 and 224 defining the confinement regions may be
composed of fluorosilicate glass. Other materials may be used to
form the various confinement regions (216, 218 and 220), including
germanosilicate, phosphosilicate, aluminosilicate, or the like, or
a combination thereof and claimed subject matter is not so limited.
Other materials may be used to form the barrier rings (222 and
224), including fused silica, borosilicate, or the like or a
combination thereof, and claimed subject matter is not so limited.
In other embodiments, the optical fibers or waveguides include or
are composed of various polymers or plastics or crystalline
materials. Generally, the core confinement regions have refractive
indices that are greater than the refractive indices of adjacent
barrier/cladding regions.
In some examples, it may be desirable to increase a number of
confinement regions in a second length of fiber to increase
granularity of beam control over beam displacements for fine-tuning
a beam profile. For example, confinement regions may be configured
to provide stepwise beam displacement.
FIG. 3 illustrates an example method of perturbing fiber 200 for
providing variable beam characteristics of an optical beam.
Changing the bend radius of a fiber may change the radial beam
position, divergence angle, and/or radiance profile of a beam
within the fiber. The bend radius of VBC fiber 200 can be decreased
from a first bend radius R.sub.1 to a second bend radius R.sub.2
about splice junction 206 by using a stepped mandrel or cone as the
perturbation assembly 210. Additionally or alternatively, the
engagement length on the mandrel(s) or cone can be varied. Rollers
250 may be employed to engage VBC fiber 200 across perturbation
assembly 210. In an example, an amount of engagement of rollers 250
with fiber 200 has been shown to shift the distribution of the
intensity profile to the outer confinement regions 218 and 220 of
fiber 200 with a fixed mandrel radius. There are a variety of other
methods for varying the bend radius of fiber 200, such as using a
clamping assembly, flexible tubing, or the like, or a combination
thereof, and claimed subject matter is not limited in this regard.
In another example, for a particular bend radius the length over
which VBC fiber 200 is bent can also vary beam characteristics in a
controlled and reproducible way. In examples, changing the bend
radius and/or length over which the fiber is bent at a particular
bend radius also modifies the intensity distribution of the beam
such that one or more modes may be shifted radially away from the
center of a fiber core.
Maintaining the bend radius of the fibers across junction 206
ensures that the adjusted beam characteristics such as radial beam
position and radiance profile of optical beam 202 will not return
to its unperturbed state before being launched into second length
of fiber 208. Moreover, the adjusted radial beam characteristics,
including position, divergence angle, and/or intensity
distribution, of adjusted beam 226 can be varied based on an extent
of decrease in the bend radius and/or the extent of the bent length
of VBC fiber 200. Thus, specific beam characteristics may be
obtained using this method.
In the current example, first length of fiber 204 having first RIP
212 is spliced at junction 206 to a second length of fiber 208
having a second RIP 214. However, it is possible to use a single
fiber having a single RIP formed to enable perturbation (e.g., by
micro-bending) of the beam characteristics of beam 202 and to
enable conservation of the adjusted beam. Such a RIP may be similar
to the RIPs shown in fibers illustrated in FIGS. 17, 18, and/or
19.
FIGS. 7-10 provide experimental results for VBC fiber 200 (shown in
FIGS. 2 and 3) and illustrate further a beam response to
perturbation of VBC fiber 200 when a perturbation assembly 210 acts
on VBC fiber 200 to bend the fiber. FIGS. 4-6 are simulations and
FIGS. 7-10 are experimental results wherein a beam from a SM 1050
nm source was launched into an input fiber (not shown) with a 40
micron core diameter. The input fiber was spliced to first length
of fiber 204.
FIG. 4 is an example graph 400 illustrating the calculated profile
of the lowest-order mode (LP.sub.01) for a first length of fiber
204 for different fiber bend radii 402, wherein a perturbation
assembly 210 involves bending VBC fiber 200. As the fiber bend
radius is decreased, an optical beam propagating in VBC fiber 200
is adjusted such that the mode shifts radially away from the center
404 of a VBC fiber 200 core (r=0 micron) toward the core/cladding
interface (located at r=100 micron in this example). Higher-order
modes (LP.sub.In) also shift with bending. Thus, for a straight or
nearly straight fiber (very large bend radius), curve 406 for
LP.sub.01 is centered at or near the center of VBC fiber 200. At a
bend radius of about 6 cm, curve 408 for LP.sub.01 is shifted to a
radial position of about 40 .mu.m from the center 406 of VBC fiber
200. At a bend radius of about 5 cm, curve 410 for LP.sub.01 is
shifted to a radial position about 50 .mu.m from the center 406 of
VBC fiber 200. At a bend radius of about 4 cm, curve 412 for
LP.sub.01 is shifted to a radial position about 60 .mu.m from the
center 406 of VBC fiber 200. At a bend radius of about 3 cm, curve
414 for LP.sub.01 is shifted to a radial position about 80 .mu.m
from the center 406 of VBC fiber 200. At a bend radius of about 2.5
cm, a curve 416 for LP.sub.01 is shifted to a radial position about
85 .mu.m from the center 406 of VBC fiber 200. Note that the shape
of the mode remains relatively constant (until it approaches the
edge of the core), which is a specific property of a parabolic RIP.
Although, this property may be desirable in some situations, it is
not required for the VBC functionality, and other RIPs may be
employed.
In an example, if VBC fiber 200 is straightened, LP.sub.01 mode
will shift back toward the center of the fiber. Thus, the purpose
of second length of fiber 208 is to "trap" or confine the adjusted
intensity distribution of the beam in a confinement region that is
displaced from the center of the VBC fiber 200. The splice between
fibers 204 and 208 is included in the bent region, thus the shifted
mode profile will be preferentially launched into one of the
ring-shaped confinement regions 218 and 220 or be distributed among
the confinement regions. FIGS. 5 and 6 illustrate this effect.
FIG. 5 illustrates an example of two-dimensional intensity
distribution at junction 206 within second length of fiber 208 when
VBC fiber 200 is nearly straight. A significant portion of
LP.sub.01 and LP.sub.In is within confinement region 216 of fiber
208. FIG. 6 illustrates the two-dimensional intensity distribution
at junction 206 within second length of fiber 208 when VBC fiber
200 is bent with a radius chosen to preferentially excite
confinement region 220 (the outermost confinement region) of second
length of fiber 208. A significant portion of LP.sub.01 and
LP.sub.In is within confinement region 220 of fiber 208.
In an example, in second length of fiber 208, confinement region
216 has a 100 micron diameter, confinement region 218 is between
120 micron and 200 micron in diameter, and confinement region 220
is between 220 micron and 300 micron diameter. Confinement regions
216, 218, and 220 are separated by 10 .mu.m thick rings of
fluorosilicate, providing an NA of 0.22 for the confinement
regions. Other inner and outer diameters for the confinement
regions, thicknesses of the rings separating the confinement
regions, NA values for the confinement regions, and numbers of
confinement regions may be employed.
Referring again to FIG. 5, with the noted parameters, when VBC
fiber 200 is straight, about 90% of the power is contained within
the central confinement region 216, and about 100% of the power is
contained within confinement regions 216 and 218. Referring now to
FIG. 6, when fiber 200 is bent to preferentially excite second ring
confinement region 220, nearly 75% of the power is contained within
confinement region 220, and more than 95% of the power is contained
within confinement regions 218 and 220. These calculations include
LP.sub.01 and two higher-order modes, which are typical in some 2-4
kW fiber lasers.
It is clear from FIGS. 5 and 6 that, in the case where a
perturbation assembly 210 acts on VBC fiber 200 to bend the fiber,
the bend radius determines the spatial overlap of the modal
intensity distribution of the first length of fiber 204 with the
different guiding confinement regions (216, 218, and 220) of the
second length of fiber 208. Changing the bend radius can thus
change the intensity distribution at the output of the second
length of fiber 208, thereby changing the diameter or spot size of
the beam, and thus changing its radiance and BPP value. This
adjustment of the spot size may be accomplished in an all-fiber
structure, involving no free-space optics and consequently may
reduce or eliminate the disadvantages of free-space optics
discussed above. Such adjustments can also be made with other
perturbation assemblies that alter bend radius, bend length, fiber
tension, temperature, or other perturbations discussed below.
In a typical materials processing system (e.g., a cutting or
welding tool), the output of the process fiber is imaged at or near
the workpiece by the process head. Varying the intensity
distribution as shown in FIGS. 5 and 6 thus enables variation of
the beam profile at the workpiece in order to tune and/or optimize
the process, as desired. Specific RIPs for the two fibers were
assumed for the purpose of the above calculations, but other RIPs
are possible, and claimed subject matter is not limited in this
regard.
FIGS. 7-10 depict experimental results (measured intensity
distributions) to illustrate further output beams for various bend
radii of VBC fiber 200 shown in FIG. 2.
In FIG. 7 when VBC fiber 200 is straight, the beam is nearly
completely confined to confinement region 216. As the bend radius
is decreased, the intensity distribution at the output shifts to
the larger diameters of confinement regions 218 and 220 located
farther away from confinement region 216--see e.g., this shift
visible in FIGS. 8-10. FIG. 8 depicts the intensity distribution
when the bend radius of VBC fiber 200 is chosen to shift the
intensity distribution preferentially to confinement region 218.
FIG. 9 depicts the experimental results when the bend radius is
further reduced and chosen to shift the intensity distribution
outward to confinement region 220 and confinement region 218. In
FIG. 10, at the smallest bend radius, the beam is nearly a "donut
mode," with most of the intensity in the outermost confinement
region 220.
Despite excitation of the confinement regions from one side at the
splice junction 206, the intensity distributions are nearly
symmetric azimuthally because of scrambling within confinement
regions as the beam propagates within the VBC fiber 200. Although
the beam will typically scramble azimuthally as it propagates,
various structures or perturbations (e.g., coils) could be included
to facilitate this process.
For the fiber parameters used in the experiment shown in FIGS.
7-10, particular confinement regions were not exclusively excited
because some intensity was present in multiple confinement regions.
This feature may enable advantageous materials processing
applications that are optimized by having a flatter or distributed
beam intensity distribution. In applications requiring cleaner
excitation of a given confinement region, different fiber RIPs
could be employed to enable this feature.
The results shown in FIGS. 7-10 pertain to the particular fibers
used in this experiment, and the details will vary depending on the
specifics of the implementation. In particular, the spatial profile
and divergence distribution of the output beam and their dependence
on bend radius will depend on the specific RIPs employed, on the
splice parameters, and on the characteristics of the laser source
launched into the first fiber.
Different fiber parameters from those shown in FIG. 2 may be used
and still be within the scope of the claimed subject matter.
Specifically, different RIPs and core sizes and shapes may be used
to facilitate compatibility with different input beam profiles and
to enable different output beam characteristics. Example RIPs for
the first length of fiber, in addition to the parabolic-index
profile shown in FIG. 2, include other graded-index profiles,
step-index, pedestal designs (i.e., nested cores with progressively
lower refractive indices with increasing distance from the center
of the fiber), and designs with nested cores with the same
refractive index value but with various NA values for the central
core and the surrounding rings. Example RIPs for the second length
of fiber, in addition to the profile shown in FIG. 2, include
confinement fibers with different numbers of confinement regions,
non-uniform confinement-region thicknesses, different and/or
non-uniform values for the thicknesses of the rings surrounding the
confinement regions, different and/or non-uniform NA values for the
confinement regions, different refractive-index values for the
high-index and low-index portions of the RIP, non-circular
confinement regions (such as elliptical, oval, polygonal, square,
rectangular, or combinations thereof), as well as other designs as
discussed in further detail with respect to FIGS. 26-28.
Furthermore, VBC fiber 200 and other examples of a VBC fiber
described herein are not restricted to use of two fibers. In some
examples, implementation may include use of one fiber or more than
two fibers. In some cases, the fiber(s) may not be axially uniform;
for example, they could include fiber Bragg gratings or long-period
gratings, or the diameter could vary along the length of the fiber.
In addition, the fibers do not have to be azimuthally symmetric,
e.g., the core(s) could have square or polygonal shapes. Various
fiber coatings (buffers) may be employed, including high-index or
index-matched coatings (which strip light at the glass-polymer
interface) and low-index coatings (which guide light by total
internal reflection at the glass-polymer interface). In some
examples, multiple fiber coatings may be used on VBC fiber 200.
FIGS. 11-16 illustrate cross-sectional views of examples of first
lengths of fiber for enabling adjustment of beam characteristics in
a VBC fiber responsive to perturbation of an optical beam
propagating in the first lengths of fiber. Some examples of beam
characteristics that may be adjusted in the first length of fiber
are: beam diameter, beam divergence distribution, BPP, intensity
distribution, luminance, M.sup.2 factor, NA, optical intensity
profile, power density profile, radial beam position, radiance,
spot size, or the like, or any combination thereof. The first
lengths of fiber depicted in FIGS. 11-16 and described below are
merely examples and do not provide an exhaustive recitation of the
variety of first lengths of fiber that may be utilized to enable
adjustment of beam characteristics in a VBC fiber assembly.
Selection of materials, appropriate RIPs, and other variables for
the first lengths of fiber illustrated in FIGS. 11-16 at least
depend on a desired beam output. A wide variety of fiber variables
are contemplated and are within the scope of the claimed subject
matter. Thus, claimed subject matter is not limited by examples
provided herein.
In FIG. 11 first length of fiber 1100 comprises a step-index
profile 1102. FIG. 12 illustrates a first length of fiber 1200
comprising a "pedestal RIP" (i.e., a core comprising a step-index
region surrounded by a larger step-index region) 1202. FIG. 13
illustrates a first length of fiber 1300 comprising a
multiple-pedestal RIP 1302.
FIG. 14A illustrates a first length of fiber 1400 comprising a
graded-index profile 1418 surrounded by a down-doped region 1404.
When the fiber 1400 is perturbed, modes may shift radially outward
in fiber 1400 (e.g., during bending of fiber 1400). Graded-index
profile 1402 may be designed to promote maintenance or even
compression of modal shape. This design may promote adjustment of a
beam propagating in fiber 1400 to generate a beam having a beam
intensity distribution concentrated in an outer perimeter of the
fiber (i.e., in a portion of the fiber core that is displaced from
the fiber axis). As described above, when the adjusted beam is
coupled into a second length of fiber having confinement regions,
the intensity distribution of the adjusted beam may be trapped in
the outermost confinement region, providing a donut shaped
intensity distribution. A beam spot having a narrow outer
confinement region may be useful to enable certain material
processing actions.
FIG. 14B illustrates a first length of fiber 1406 comprising a
graded-index profile 1414 surrounded by a down-doped region 1408
similar to that of fiber 1400. However, fiber 1406 includes a
divergence structure 1410 (a lower-index region) as can be seen in
profile 1412. The divergence structure 1410 is an area of material
with a lower refractive index than that of the surrounding core. As
the beam is launched into first length of fiber 1406, refraction
from divergence structure 1410 causes the beam divergence to
increase in first length of fiber 1406. The amount of increased
divergence depends on the amount of spatial overlap of the beam
with the divergence structure 1410 and the magnitude of the index
difference between the divergence structure 1410 and the core
material. Divergence structure 1410 can have a variety of shapes,
depending on the input divergence distribution and desired output
divergence distribution. In an example, divergence structure 1410
has a triangular or graded index shape.
FIG. 15 illustrates a first length of fiber 1500 comprising a
parabolic-index central region 1502 surrounded by a constant-index
region 1504. Between the constant-index region 1504 and the
parabolic-index central region 1502 is a lower-index annular layer
(or lower-index ring or annulus) 1506 surrounding the
parabolic-index central region 1502. The lower-index annulus 1506
helps guide a beam propagating in fiber 1500. When the propagating
beam is perturbed, modes shift radially outward in fiber 1500
(e.g., during bending of fiber 1500). As one or more modes shift
radially outward, parabolic-index region 1502 promotes retention of
modal shape. When the modes reach the constant-index region 1504 at
outer portions of a RIP 1510, they will be compressed against the
lower-index ring 1506, which (in comparison to the first fiber RIP
shown in FIGS. 14A and 14B) may cause preferential excitation of
the outermost confinement region in the second fiber. In one
implementation, this fiber design works with a confinement fiber
having a central step-index core and a single annular core. The
parabolic-index portion 1502 of the RIP 1510 overlaps with the
central step-index core of the confinement fiber. The
constant-index portion 1504 overlaps with the annular core of the
confinement fiber. The constant-index portion 1504 of the first
fiber is intended to make it easier to move the beam into overlap
with the annular core by bending. This fiber design also works with
other designs of the confinement fiber.
FIG. 16 illustrates a first length of fiber 1600 comprising guiding
regions 1604, 1606, 1608, and 1616 bounded by lower-index layers
1610, 1612, and 1614 where the indexes of the lower-index layers
1610, 1612, and 1614 are stepped or, more generally, do not all
have the same value. The stepped-index layers may serve to bound
the beam intensity to certain guiding regions (1604, 1606, 1608,
and 1616) when the perturbation assembly 210 (see FIG. 2) acts on
the fiber 1600. In this way, adjusted beam light may be trapped in
the guiding regions over a range of perturbation actions (such as
over a range of bend radii, a range of bend lengths, a range of
micro-bending pressures, and/or a range of acousto-optical
signals), allowing for a certain degree of perturbation tolerance
before a beam intensity distribution is shifted to a more distant
radial position in fiber 1600. Thus, variation in beam
characteristics may be controlled in a step-wise fashion. The
radial widths of the guiding regions 1604, 1606, 1608, and 1616 may
be adjusted to achieve a desired ring width, as may be required by
an application. Also, a guiding region can have a thicker radial
width to facilitate trapping of a larger fraction of the incoming
beam profile if desired. Region 1606 is an example of such a
design.
FIGS. 17-21 depict examples of fibers configured to enable
maintenance and/or confinement of adjusted beam characteristics in
the second length of fiber (e.g., fiber 208). These fiber designs
are referred to as "ring-shaped confinement fibers" because they
contain a central core surrounded by annular or ring-shaped cores.
These designs are merely examples and not an exhaustive recitation
of the variety of fiber RIPs that may be used to enable maintenance
and/or confinement of adjusted beam characteristics within a fiber.
Thus, claimed subject matter is not limited to the examples
provided herein. Moreover, any of the first lengths of fiber
described above with respect to FIGS. 11-16 may be combined with
any of the second length of fiber described FIGS. 17-21.
FIG. 17 illustrates a cross-sectional view of an example second
length of fiber for maintaining and/or confining adjusted beam
characteristics in a VBC fiber assembly. As the perturbed beam is
coupled from a first length of fiber to a second length of fiber
1700, the second length of fiber 1700 may maintain at least a
portion of the beam characteristics adjusted in response to
perturbation in the first length of fiber within one or more of
confinement regions 1704, 1706, and/or 1708. Fiber 1700 has a RIP
1702. Each of confinement regions 1704, 1706, and/or 1708 is
bounded by a lower index layer 1710 and/or 1712. This design
enables second length of fiber 1700 to maintain the adjusted beam
characteristics. As a result, a beam output by fiber 1700 will
substantially maintain the received adjusted beam as modified in
the first length of fiber giving the output beam adjusted beam
characteristics, which may be customized to a processing task or
other application.
Similarly, FIG. 18 depicts a cross-sectional view of an example
second length of fiber 1800 for maintaining and/or confining beam
characteristics adjusted in response to perturbation in the first
length of fiber in a VBC fiber assembly. Fiber 1800 has a RIP 1802.
However, confinement regions 1808, 1810, and/or 1812 have different
thicknesses from the thicknesses of confinement regions 1704, 1706,
and 1708. Each of confinement regions 1808, 1810, and/or 1812 is
bounded by a lower index layer 1804 and/or 1806. Varying the
thicknesses of the confinement regions (and/or barrier regions)
enables tailoring or optimization of a confined adjusted radiance
profile by selecting particular radial positions within which to
confine an adjusted beam.
FIG. 19 depicts a cross-sectional view of an example second length
of fiber 1900 having a RIP 1902 for maintaining and/or confining an
adjusted beam in a VBC fiber assembly configured to provide
variable beam characteristics. In this example, the number and
thicknesses of confinement regions 1904, 1906, 1908, and 1910 are
different from those of fiber 1700 and 1800; and the barrier layers
1912, 1914, and 1916 are of varied thicknesses as well.
Furthermore, confinement regions 1904, 1906, 1908, and 1910 have
different indexes of refraction; and barrier layers 1912, 1914, and
1916 have different indexes of refraction as well. This design may
further enable a more granular or optimized tailoring of the
confinement and/or maintenance of an adjusted beam radiance to
particular radial locations within fiber 1900. As the perturbed
beam is launched from a first length of fiber to second length of
fiber 1900, the modified beam characteristics of the beam (having
an adjusted intensity distribution, radial position, and/or
divergence angle, or the like, or a combination thereof) is
confined within a specific radius by one or more of confinement
regions 1904, 1906, 1908, and/or 1910 of second length of fiber
1900.
As noted previously, the divergence angle of a beam may be
conserved or adjusted and then conserved in the second length of
fiber. There are a variety of methods to change the divergence
angle of a beam. The following are examples of fibers configured to
enable adjustment of the divergence angle of a beam propagating
from a first length of fiber to a second length of fiber in a fiber
assembly for varying beam characteristics. However, these are
merely examples and not an exhaustive recitation of the variety of
methods that may be used to enable adjustment of divergence of a
beam. Thus, claimed subject matter is not limited to the examples
provided herein.
FIG. 20 depicts a cross-sectional view of an example second length
of fiber 2000 having a RIP 2002 for modifying, maintaining, and/or
confining beam characteristics adjusted in response to perturbation
in the first length of fiber. In this example, second length of
fiber 2000 is similar to the previously described second lengths of
fiber and forms a portion of the VBC fiber assembly for delivering
variable beam characteristics as discussed above. There are three
confinement regions 2004, 2006, and 2008 and three barrier layers
2010, 2012, and 2016. Second length of fiber 2000 also has a
divergence structure 2014 situated within the confinement region
2006. The divergence structure 2014 is an area of material with a
lower refractive index than that of the surrounding confinement
region. As the beam is launched into second length of fiber 2000,
refraction from divergence structure 2014 causes the beam
divergence to increase in second length of fiber 2000. The amount
of increased divergence depends on the amount of spatial overlap of
the beam with the divergence structure 2014 and the magnitude of
the index difference between the divergence structure 2014 and the
core material. By adjusting the radial position of the beam near
the launch point into the second length of fiber 2000, the
divergence distribution may be varied. The adjusted divergence of
the beam is conserved in fiber 2000, which is configured to deliver
the adjusted beam to the process head, another optical system
(e.g., fiber-to-fiber coupler or fiber-to-fiber switch), the
workpiece, or the like, or a combination thereof. In an example,
divergence structure 2014 may have an index dip of about
10.sup.-5-3.times.10.sup.-2 with respect to the surrounding
material. Other values of the index dip may be employed within the
scope of this disclosure, and claimed subject matter is not so
limited.
FIG. 21 depicts a cross-sectional view of an example second length
of fiber 2100 having a RIP 2102 for modifying, maintaining, and/or
confining beam characteristics adjusted in response to perturbation
in the first length of fiber. Second length of fiber 2100 forms a
portion of a VBC fiber assembly for delivering a beam having
variable characteristics. In this example, there are three
confinement regions 2104, 2106, and 2108 and three barrier layers
2110, 2112, and 2116. Second length of fiber 2100 also has a
plurality of divergence structures 2114 and 2118. The divergence
structures 2114 and 2118 are areas of graded lower index material.
As the beam is launched from the first length fiber into second
length of fiber 2100, refraction from divergence structures 2114
and 2118 causes the beam divergence to increase. The amount of
increased divergence depends on the amount of spatial overlap of
the beam with the divergence structure and the magnitude of the
index difference between the divergence structure 2114 and/or 2118
and the surrounding core material of confinement regions 2106 and
2104 respectively. By adjusting the radial position of the beam
near the launch point into the second length of fiber 2100, the
divergence distribution may be varied. The design shown in FIG. 21
allows the intensity distribution and the divergence distribution
to be varied somewhat independently by selecting both a particular
confinement region and the divergence distribution within that
confinement region (because each confinement region may include a
divergence structure). The adjusted divergence of the beam is
conserved in fiber 2100, which is configured to deliver the
adjusted beam to the process head, another optical system, or the
workpiece. Forming the divergence structures 2114 and 2118 with a
graded or non-constant index enables tuning of the divergence
profile of the beam propagating in fiber 2100. An adjusted beam
characteristic such as a radiance profile and/or divergence profile
may be conserved as it is delivered to a process head by the second
fiber. Alternatively, an adjusted beam characteristic such as a
radiance profile and/or divergence profile may be conserved or
further adjusted as it is routed by the second fiber through a
fiber-to-fiber coupler (FFC) and/or fiber-to-fiber switch (FFS) and
to a process fiber, which delivers the beam to the process head or
the workpiece.
FIGS. 26-28 are cross-sectional views illustrating examples of
fibers and fiber RIPs configured to enable maintenance and/or
confinement of adjusted beam characteristics of a beam propagating
in an azimuthally asymmetric second length of fiber, wherein the
beam characteristics are adjusted responsive to perturbation of a
first length of fiber coupled to the second length of fiber and/or
perturbation of the beam by a perturbation device 110. These
azimuthally asymmetric designs are merely examples and are not an
exhaustive recitation of the variety of fiber RIPs that may be used
to enable maintenance and/or confinement of adjusted beam
characteristics within an azimuthally asymmetric fiber. Thus,
claimed subject matter is not limited to the examples provided
herein. Moreover, any of a variety of first lengths of fiber (e.g.,
like those described above) may be combined with any azimuthally
asymmetric second length of fiber (e.g., like those described in
FIGS. 26-28).
FIG. 26 illustrates RIPs at various azimuthal angles of a
cross-section through an elliptical fiber 2600. At a first
azimuthal angle 2602, fiber 2600 has a first RIP 2604. At a second
azimuthal angle 2606 that is rotated 45.degree. from first
azimuthal angle 2602, fiber 2600 has a second RIP 2608. At a third
azimuthal angle 2610 that is rotated another 45.degree. from second
azimuthal angle 2606, fiber 2600 has a third RIP 2612. First,
second, and third RIPs 2604, 2608, and 2612 are all different.
FIG. 27 illustrates RIPs at various azimuthal angles of a
cross-section through a multicore fiber 2700. At a first azimuthal
angle 2702, fiber 2700 has a first RIP 2704. At a second azimuthal
angle 2706, fiber 2700 has a second RIP 2708. First and second RIPs
2704 and 2708 are different. In an example, perturbation device 110
may act in multiple planes in order to launch the adjusted beam
into different regions of an azimuthally asymmetric second
fiber.
FIG. 28 illustrates RIPs at various azimuthal angles of a
cross-section through a fiber 2800 having at least one crescent
shaped core. In some cases, the corners of the crescent may be
rounded, flattened, or otherwise shaped, which may minimize optical
loss. At a first azimuthal angle 2802, fiber 2800 has a first RIP
2804. At a second azimuthal angle 2806, fiber 2800 has a second RIP
2808. First and second RIPs 2804 and 2808 are different.
FIG. 22A illustrates an example of a laser system 2200 including a
VBC fiber assembly 2202 configured to provide variable beam
characteristics. VBC fiber assembly 2202 comprises a first length
of fiber 104, a second length of fiber 108, and a perturbation
device 110. VBC fiber assembly 2202 is disposed between feeding
fiber 2212 (i.e., the output fiber from the laser source) and VBC
delivery fiber 2240. VBC delivery fiber 2240 may comprise second
length of fiber 108 or an extension of second length of fiber 108
that modifies, maintains, and/or confines adjusted beam
characteristics. Beam 2210 is coupled into VBC fiber assembly 2202
via feeding fiber 2212. Fiber assembly 2202 is configured to vary
the characteristics of beam 2210 in accordance with the various
examples described above. The output of fiber assembly 2202 is
adjusted beam 2214, which is coupled into VBC delivery fiber 2240.
VBC delivery fiber 2240 delivers adjusted beam 2214 to a free-space
optics assembly 2208, which then couples beam 2214 into a process
fiber 2204. Adjusted beam 2214 is then delivered to process head
2206 by process fiber 2204. The process head can include guided
wave optics (such as fibers and fiber coupler), free space optics
(such as lenses, mirrors, optical filters, diffraction gratings),
and/or beam scan assemblies (such as galvanometer scanners,
polygonal mirror scanners, or other scanning systems) that are used
to shape the beam 2214 and deliver the shaped beam to a
workpiece.
In laser system 2200, one or more of the free-space optics of
assembly 2208 may be disposed in an FFC or other beam coupler 2216
to perform a variety of optical manipulations of an adjusted beam
2214 (represented in FIG. 22A with different dashing from that of
beam 2210). For example, free-space optics assembly 2208 may
preserve the adjusted beam characteristics of beam 2214. Process
fiber 2204 may have the same RIP as VBC delivery fiber 2240. Thus,
the adjusted beam characteristics of adjusted beam 2214 may be
preserved all the way to process head 2206. Process fiber 2204 may
comprise a RIP similar to any of the second lengths of fiber
described above, including confinement regions.
Alternatively, as illustrated in FIG. 22B, free-space optics
assembly 2208 may change the adjusted beam characteristics of beam
2214 by, for example, increasing or decreasing the divergence
and/or the spot size of beam 2214 (e.g., by magnifying or
demagnifying beam 2214) and/or otherwise further modifying adjusted
beam 2214. Furthermore, process fiber 2204 may have a different RIP
than VBC delivery fiber 2240. Accordingly, the RIP of process fiber
2204 may be selected to preserve additional adjustment of adjusted
beam 2214 made by the free-space optics of assembly 2208 to
generate a twice adjusted beam 2224 (represented in FIG. 22B with
different dashing from that of beam 2214).
FIG. 23 illustrates an example of a laser system 2300 including VBC
fiber assembly 2302 disposed between a feeding fiber 2312 and a VBC
delivery fiber 2340. During operation, a beam 2310 is coupled into
VBC fiber assembly 2302 via feeding fiber 2312. Fiber assembly 2302
includes a first length of fiber 104, a second length of fiber 108,
and a perturbation device 110 and is configured to vary
characteristics of beam 2310 in accordance with the various
examples described above. Fiber assembly 2302 generates an adjusted
beam 2314 output by VBC delivery fiber 2340. VBC delivery fiber
2340 comprises a second length of fiber 108 of fiber for modifying,
maintaining, and/or confining adjusted beam characteristics in a
fiber assembly 2302 in accordance with the various examples
described above (see FIGS. 17-21, for example). VBC delivery fiber
2340 couples adjusted beam 2314 into a beam switch (FFS) 2332,
which then couples its various output beams to one or more of
multiple process fibers 2304, 2320, and 2322. Process fibers 2304,
2320, and 2322 deliver adjusted beams 2314, 2328, and 2330 to
respective process heads 2306, 2324, and 2326.
In an example, beam switch 2332 includes one or more sets of
free-space optics 2308, 2316, and 2318 configured to perform a
variety of optical manipulations of adjusted beam 2314. Free-space
optics 2308, 2316, and 2318 may preserve or vary adjusted beam
characteristics of beam 2314. Thus, adjusted beam 2314 may be
maintained by the free-space optics or adjusted further. Process
fibers 2304, 2320, and 2322 may have the same or a different RIP as
that of VBC delivery fiber 2340, depending on whether it is
desirable to preserve or further modify a beam passing from the
free-space optics assemblies 2308, 2316, and 2318 to respective
process fibers 2304, 2320, and 2322. In other examples, one or more
beam portions of beam 2310 are coupled to a workpiece without
adjustment, or different beam portions are coupled to respective
VBC fiber assemblies so that beam portions associated with a
plurality of beam characteristics can be provided for simultaneous
workpiece processing. Alternatively, beam 2310 can be switched to
one or more of a set of VBC fiber assemblies.
Routing adjusted beam 2314 through any of free-space optics
assemblies 2308, 2316, and 2318 enables delivery of a variety of
additionally adjusted beams to process heads 2206, 2324, and 2326.
Therefore, laser system 2300 provides additional degrees of freedom
for varying the characteristics of a beam, as well as switching the
beam between process heads ("time sharing") and/or delivering the
beam to multiple process heads simultaneously ("power
sharing").
For example, free-space optics in beam switch 2332 may direct
adjusted beam 2314 to free-space optics assembly 2316 configured to
preserve the adjusted characteristics of beam 2314. Process fiber
2304 may have the same RIP as that of VBC delivery fiber 2340.
Thus, the beam delivered to process head 2306 will be a preserved
adjusted beam 2314.
In another example, beam switch 2332 may direct adjusted beam 2314
to free-space optics assembly 2318 configured to preserve the
adjusted characteristics of adjusted beam 2314. Process fiber 2320
may have a different RIP from that of VBC delivery fiber 2340 and
may be configured with divergence altering structures as described
with respect to FIGS. 20 and 21 to provide additional adjustments
to the divergence distribution of beam 2314. Thus, the beam
delivered to process head 2324 will be a twice adjusted beam 2328
having a different beam divergence profile from that of adjusted
beam 2314.
Process fibers 2304, 2320, and/or 2322 may comprise a RIP similar
to any of the second lengths of fiber described above, including
confinement regions or a wide variety of other RIPs, and claimed
subject matter is not limited in this regard.
In yet another example, free-space optics switch 2332 may direct
adjusted beam 2314 to free-space optics assembly 2308 configured to
change the beam characteristics of adjusted beam 2314. Process
fiber 2322 may have a different RIP from that of VBC delivery fiber
2340 and may be configured to preserve (or alternatively further
modify) the new further adjusted characteristics of beam 2314.
Thus, the beam delivered to process head 2326 will be a twice
adjusted beam 2330 having different beam characteristics (due to
the adjusted divergence profile and/or intensity profile) from
those of adjusted beam 2314.
In FIGS. 22A, 22B, and 23, the optics in the FFC or FFS may adjust
the spatial profile and/or divergence profile by magnifying or
demagnifying the beam 2214 before launching into the process fiber.
They may also adjust the spatial profile and/or divergence profile
via other optical transformations. They may also adjust the launch
position into the process fiber. These methods may be used alone or
in combination.
FIGS. 22A, 22B, and 23 merely provide examples of combinations of
adjustments to beam characteristics using free-space optics and
various combinations of fiber RIPs to preserve or modify adjusted
beams 2214 and 2314. The examples provided above are not exhaustive
and are meant for illustrative purposes only. Thus, claimed subject
matter is not limited in this regard.
FIG. 24 illustrates various examples of perturbation devices,
assemblies or methods (for simplicity referred to collectively
herein as "perturbation device 110") for perturbing a VBC fiber 200
and/or an optical beam propagating in VBC fiber 200 according to
various examples provided herein. Perturbation device 110 may be
any of a variety of devices, methods, and/or assemblies configured
to enable adjustment of beam characteristics of a beam propagating
in VBC fiber 200. In an example, perturbation device 110 may be a
mandrel 2402, a micro-bend 2404 in the VBC fiber, flexible tubing
2406, an acousto-optic transducer 2408, a thermal device 2410, a
piezo-electric device 2412, a grating 2414, a clamp 2416 (or other
fastener), or the like, or any combination thereof. These are
merely examples of perturbation devices 100 and not an exhaustive
listing of perturbation devices 100, and claimed subject matter is
not limited in this regard.
Mandrel 2402 may be used to perturb VBC fiber 200 by providing a
form about which VBC fiber 200 may be bent. As discussed above,
reducing the bend radius of VBC fiber 200 moves the intensity
distribution of the beam radially outward. In some examples,
mandrel 2402 may be stepped or conically shaped to provide discrete
bend radii levels. Alternatively, mandrel 2402 may comprise a cone
shape without steps to provide continuous bend radii for more
granular control of the bend radius. The radius of curvature of
mandrel 2402 may be constant (e.g., a cylindrical form) or
non-constant (e.g., an oval-shaped form). Similarly, flexible
tubing 2406, clamps 2416 (or other varieties of fasteners), or
rollers 250 may be used to guide and control the bending of VBC
fiber 200 about mandrel 2402. Furthermore, changing the length over
which the fiber is bent at a particular bend radius also may modify
the intensity distribution of the beam. VBC fiber 200 and mandrel
2402 may be configured to change the intensity distribution within
the first fiber predictably (e.g., in proportion to the length over
which the fiber is bent and/or the bend radius). Rollers 250 may
move up and down along a track 2442 on a platform 2434 to change
the bend radius of VBC fiber 200.
Clamps 2416 (or other fasteners) may be used to guide and control
the bending of VBC fiber 200 with or without a mandrel 2402. Clamps
2416 may move up and down along a track 2442 or a platform 2446.
Clamps 2416 may also swivel to change bend radius, tension, or
direction of VBC fiber 200. A controller 2448 may control the
movement of clamps 2416.
In another example, perturbation device 110 may be flexible tubing
2406 and may guide bending of VBC fiber 200 with or without a
mandrel 2402. Flexible tubing 2406 may encase VBC fiber 200. Tubing
2406 may be made of a variety of materials and may be manipulated
using piezoelectric transducers controlled by a controller 2444. In
another example, clamps or other fasteners may be used to move
flexible tubing 2406.
Micro-bend 2404 in VBC fiber is a local perturbation caused by
lateral mechanical stress on the fiber. Micro-bending can cause one
or both of mode coupling and transitions from one confinement
region to another confinement region within a fiber, resulting in
varied beam characteristics of the beam propagating in a VBC fiber
200. Mechanical stress may be applied by an actuator 2436 that is
controlled by controller 2440. For example, VBC perturbative device
110 can be configured to control in one axis or two axes the beam
propagation path in VBC fiber 200 by imparting at selected radial
locations micro-bend 2404 to VBC fiber 200. According to one
embodiment, actuator 2436 includes two actuator probes 2436a and
2436b positioned to apply mechanical stress to VBC fiber 200 in
orthogonal directions and thereby direct the beam propagating in
VBC fiber 200 to any location in a two-dimensional space. In other
embodiments several azimuthally spaced-apart probes (see e.g., FIG.
29, described later) are provided to apply force at discrete angles
around a circumference so as to modify a beam propagation path.
However, these are merely examples of methods for inducing
mechanical stress in fiber 200 and claimed subject matter is not
limited in this regard. Skilled persons will appreciate that
various other techniques for beam steering are also suitable.
Acousto-optic transducer (AOT) 2408 may be used to induce
perturbation of a beam propagating in the VBC fiber using an
acoustic wave. The perturbation is caused by the modification of
the refractive index of the fiber by the oscillating mechanical
pressure of an acoustic wave. The period and strength of the
acoustic wave are related to the acoustic wave frequency and
amplitude, allowing dynamic control of the acoustic perturbation.
Thus, a perturbation assembly 110 including AOT 2408 may be
configured to vary the beam characteristics of a beam propagating
in the fiber. In an example, a piezo-electric transducer 2418 may
create the acoustic wave and may be controlled by a controller or
driver 2420. The acoustic wave induced in AOT 2408 may be modulated
to change and/or control the beam characteristics of the optical
beam in VBC 200 in real-time. However, this is merely an example of
a method for creating and controlling an AOT 2408, and claimed
subject matter is not limited in this regard.
Thermal device 2410 may be used to induce perturbation of a beam
propagating in VBC fiber using heat. The perturbation is caused by
the modification of the RIP of the fiber induced by heat.
Perturbation may be dynamically controlled by controlling an amount
of heat transferred to the fiber and the length over which the heat
is applied. Thus, a perturbation assembly 110 including thermal
device 2410 may be configured to vary a range of beam
characteristics. Thermal device 2410 may be controlled by a
controller 2450.
Piezo-electric transducer 2412 may be used to induce perturbation
of a beam propagating in a VBC fiber using piezoelectric action.
The perturbation is caused by the modification of the RIP of the
fiber induced by a piezoelectric material attached to the fiber.
The piezoelectric material in the form of a jacket around the bare
fiber may apply tension or compression to the fiber, modifying its
refractive index via the resulting changes in density. Perturbation
may be dynamically controlled by controlling a voltage to the
piezo-electric device 2412. Thus, a perturbation assembly 110
including piezo-electric transducer 2412 may be configured to vary
the beam characteristics over a particular range.
In an example, piezo-electric transducer 2412 may be configured to
displace VBC fiber 200 in a variety of directions (e.g., axially,
radially, and/or laterally) depending on a variety of factors,
including how the piezo-electric transducer 2412 is attached to VBC
fiber 200, the direction of the polarization of the piezo-electric
materials, the applied voltage, etc. Additionally, bending of VBC
fiber 200 is possible using the piezo-electric transducer 2412. For
example, driving a length of piezo-electric material having
multiple segments comprising opposing electrodes can cause a
piezoelectric transducer 2412 to bend in a lateral direction.
Voltage applied to piezoelectric transducer 2412 by an electrode
2424 may be controlled by a controller 2422 to control displacement
of VBC fiber 200. Displacement may be modulated to change and/or
control the beam characteristics of the optical beam in VBC 200 in
real-time. However, this is merely an example of a method of
controlling displacement of a VBC fiber 200 using a piezo-electric
transducer 2412 and claimed subject matter is not limited in this
regard.
Gratings 2414 may be used to induce perturbation of a beam
propagating in a VBC fiber 200. A grating 2414 can be written into
a fiber by inscribing a periodic variation of the refractive index
into the core. Gratings 2414 such as fiber Bragg gratings can
operate as optical filters or as reflectors. A long-period grating
can induce transitions among co-propagating fiber modes. The
radiance, intensity profile, and/or divergence profile of a beam
comprised of one or more modes can thus be adjusted using a
long-period grating to couple one or more of the original modes to
one or more different modes having different radiance and/or
divergence profiles. Adjustment is achieved by varying the
periodicity or amplitude of the refractive index grating. Methods
such as varying the temperature, bend radius, and/or length (e.g.,
stretching) of the fiber Bragg grating can be used for such
adjustment. VBC fiber 200 having gratings 2414 may be coupled to a
stage 2426. Stage 2426 may be configured to execute any of a
variety of functions and may be controlled by a controller 2428.
For example, stage 2426 may be coupled to VBC fiber 200 with
fasteners 2430 and may be configured to stretch and/or bend VBC
fiber 200 using fasteners 2430 for leverage. Stage 2426 may have an
embedded thermal device and may change the temperature of VBC fiber
200.
FIG. 25 illustrates an example process 2500 for adjusting and/or
maintaining beam characteristics within a fiber without the use of
free-space optics to adjust the beam characteristics. In block
2502, a first length of fiber and/or an optical beam are perturbed
to adjust one or more optical beam characteristics. Process 2500
moves to block 2504, where the optical beam is launched into a
second length of fiber. Process 2500 moves to block 2506, where the
optical beam having the adjusted beam characteristics is propagated
in the second length of fiber. Process 2500 moves to block 2508,
where at least a portion of the one or more beam characteristics of
the optical beam are maintained within one or more confinement
regions of the second length of fiber. The first and second lengths
of fiber may be comprised of the same fiber, or they may be
different fibers.
Additive processes (e.g., powered jet or bed deposition) could be
preceded or followed by one or more of the following processes:
drilling, hardening, marking, ablation, cladding, thermal (e.g.,
heat) treating, and cutting. A result of one such combination of
processes is illustrated in a lower portion of FIG. 29, which shows
an enlarged view of a plateau region 2900 that has been deposited
on a workpiece (e.g., one or more of metals, metal alloys,
polymers, ceramics, and combinations thereof) using a laser beam
2910 exhibiting first beam characteristics 2920 (e.g., defining a
large spot size having a higher BPP). A small trench 2926 has been
subsequently cut into a flat top 2928 of plateau region 2900 using
laser beam 2910 exhibiting second beam characteristics 2930 (e.g.,
defining a small spot size having a lower BPP).
By employing first beam characteristics 2920 to form plateau region
2900, fewer passes of an otherwise narrower beam are needed.
Conversely, by employing second beam characteristics 2930 to cut
trench 2926, a more precise feature is formed than would have been
possible with a wider beam. Skilled persons will appreciate that
there are many variations of multi-operation processes in which
material is added during one process and removed or thermally
treated during another process. Moreover, the terms
multi-operation, multi-function, and multi-purpose are sometimes
used as synonyms, but the term multi-operation is intended to be
the broadest term of the three. For example, multi-operation
encompasses two processing steps that might have the same function
(e.g., back-to-back deposition functions in which the latter of the
two uses a refined BPP for smaller features).
VBC techniques, such as those described previously, streamline the
switch between the aforementioned different beam characteristics
that facilitate complementary laser process operations performed
using a single laser source. For example, FIG. 29 shows a
multi-operation optical beam delivery device 2950 to facilitate
different laser process operations by modification of beam
characteristics of laser beam 2910. According to one embodiment,
the different laser process operations include laser deposition and
pre- or post-processing of a deposition region. A deposition region
means any region that has been or will be processed, directly or
indirectly, with an optical beam or deposition media applied by the
optical beam to the region.
A laser source 2960 is employed to provide an optical beam that is
adjustable by a beam characteristic conditioner 2964. According to
one embodiment, laser source 2960 and beam characteristic
conditioner 2964 define an all-in-fiber, waveguide delivered laser
source 2968 configured to manipulate beam characteristics along the
lines described previously in this disclosure. In other words,
laser source 2960 is a fiber-delivered laser source including the
all-in-fiber techniques described, among other places, with
reference to FIGS. 4-10 for manipulating beam characteristics. In
other embodiments, beam characteristics of an optical beam are
modified by using free space optics, a zoom lens, diffractive
optical elements, multicore fiber, and other types of beam
characteristic conditioners.
A delivery fiber 2970 coupled to, or otherwise forming an output
fiber of, beam characteristic conditioner 2964 provides laser beam
2910 to a process head 2980 adapted for performing deposition
functions as well as pre- or post-processing functions. Delivery
fiber 2970 allows waveguide delivered laser source 2968 to be
spaced apart from process head 2980, which includes processing
optics 2982 (explained later with reference to FIG. 30) and a
multi-operation nozzle 2986 (explained later with reference to
FIGS. 31-33).
FIG. 29 also shows a controller 2990 adapted to coordinate beam
characteristics for the different processes. For example,
controller 2990 generates for mandrel 2402 (FIG. 24) signals
indicating an amount of movement of mandrel 2402 that imparts a
bend to fiber 200 so as to control BPP based on the amount of bend,
and thereby changes laser beam 2910 from being configured for a
deposition task to being configured for some other processing task.
Controller 2990, according to some other embodiments, coordinates
functions of beam characteristic conditioner 2964 (e.g., mandrel
2402) with multi-operation nozzle 2986 that is the subject of FIGS.
31-33. For example, controller 2990 optionally coordinates one or
more of deposition media feed rate, mass flow, gas pressure, mixing
of gas composition, process speed, and switching between ejecting
gas or media from various orifices (see e.g., orifices shown in
FIG. 32 or 33). Examples of types of controller hardware suitable
for coordinating beam characteristic conditioner 2964, optional
multi-operation nozzle 2986, and other optional equipment (such as
an optional zoom optic shown in FIG. 30) include mass flow
controllers, programmable logic controllers (PLCs), and personal
computer (PC)-based controller hardware. For example, one type of
mass flow controller, which could be modified to also control
mandrel 2402 and perforce beam characteristics, is a Metco M1100C
available from Oerlikon Metco of Pfaffikon, Switzerland.
FIG. 29 shows process head 2980 including a collimator lens 2992
and a focus lens 2996. Focus lens 2996 is typically not fixed in
position--being translatable along the vertical axis in FIG.
29--and collimator lens 2992 is physically fixed in place. This
configuration is referred to as a so-called fixed optical
configuration due to its fixed overall magnification. In contrast,
FIG. 30 shows a process head 3000 supporting an optional zoom optic
3010, having a separate collimating lens 3020 and focus lens 3024,
to establish a so-called variable optical configuration having a
variable overall magnification. A variable optical configuration is
coordinated or synchronized with beam characteristic conditioner
2964 configurations to provide users with a wider variety of
available processes or modifiable process parameters. For example,
according to some other embodiments, controller 2990 establishes an
initial function of beam characteristic conditioner 2964 (e.g.,
mandrel 2402) defined by a first BPP, and then controller 2990
refines that function based on a zoom level established by
adjusting optional zoom optic 3010 to refine power density applied
to a workpiece.
FIG. 30 also shows another embodiment wherein separate
single-function nozzles are used in addition to or as an
alternative to multi-operation nozzle 2986. For example, following
an optional use of multi-operation nozzle 2986, a first
single-purpose nozzle 3030 used for a first dedicated function
replaces multi-operation nozzle 2986. Then, a second single-purpose
nozzle 3034 is installed in place of the first single-purpose
nozzle 3030 for use with a second dedicated function that is
different, and so forth. Thus, a user or machine replaces nozzles
in order to perform various specialized deposition and pre- or
post-processing functions.
With respect to multi-operation nozzle 2986, FIGS. 31 and 32 show
in greater detail how process head 2980 (FIG. 29) is, according to
one embodiment, configured to perform a variety of functions
including providing carrier gases, powder, or other media. For
example, multi-operation nozzle 2986 includes multiple
concentrically arranged orifices 3100 (FIG. 31) for providing
different materials. A central orifice 3110 provides a pathway for
laser beam 2910 and one or more gases deliverable at selectable
pressures and flow rates (e.g., gas configuration A). An adjacent
orifice 3120, which is radially displaced from and concentrically
encompasses central orifice 3110, carries a second gas that is
deliverable at selectable pressures and flow rates (e.g., gas
configuration B, optionally different from gas configuration A). In
this example, gas configuration B carries powered media 3124. A
third orifice 3130 and a fourth orifice 3140 provide, respectively,
a third gas configuration (e.g., gas configuration C) and a mixture
of a different deposition media carried by a fourth gas
configuration (e.g., gas configuration D). Skilled persons will
appreciate, however, that not all orifices need be employed, and
some nozzles could have a greater or lesser number of orifices.
More generally, various other materials may controllably flow
through orifices of a multi-operation nozzle. Thus, materials
broadly means deposition media (or simply, media) or gases used for
material chemistry modification or delivery of the material media
(e.g. blown powder). Deposition media include wire, rod, strip,
sheet, powder, slurry, or combinations thereof. Gases include
inert, active, oxidizing, nitriding, or combinations thereof.
FIG. 32 also shows a wire-feed site 3210 to controllably extend
wire to be laser deposited on a workpiece. Other nozzles may
include one or more tubes for feeding wire or a strip-shaped tube.
In other words, instead of having a round port for a round feed
wire, the port is shaped to match any shape of material to be
deposited. For a strip, the shape of the port could be rectangular
and sized to match material fed through the port, i.e., about 1
millimeter (mm).times.0.2 mm.
FIG. 33 shows an end view of another multi-operation nozzle 3300
having mutually azimuthally spaced apart orifices. According to one
embodiment, a central orifice 3306 provides gas configuration A and
a pathway for laser beam 2910 (FIG. 29), a first set of orifices
3310 provides gas configuration B, a second set 3320 provides gas
configuration C, and a third set 3330 provides gas configuration D.
As described previously, some of the orifices may be dedicated to
delivering gases at different pressures or flows whereas other
orifices could be dedicated to delivering deposition media. In some
embodiments, beams from different confinement regions are
deliverable to different orifices. Skilled persons will also
appreciate that the members of the sets need not be spaced apart in
a radially symmetric manner. Also, in some embodiments, one or more
orifices may even deliver wire through a tube for feed wire or a
strip-shaped tube for strip, as described with reference to FIG.
32.
Turning back to controller 2990, it is noted that each orifice or
family of orifices in a multi-operation nozzle may be independently
controllable. Also, multiple different sets may be controllable to
provide material contemporaneously, as in the case of orifices 3110
and 3120 (FIG. 31), or at separate times, as in the case of the
separate nozzles (FIG. 30).
The present inventors recognized that employing a zoom optic in a
process head as a sole means to produce beam modifications also
produces potentially undesirable reciprocal changes of both the
spatial and angular distribution of the beam. In other words, a
product of the values representing these distributions remains
constant as the zoom optic is adjusted, which is undesirable in
some processes for reasons set forth in the following paragraph.
The reciprocal property of a zoom optic stems from its inherent
conservation of brightness as modifications are made to the level
of zoom. Thus, changing a spot size by a factor of two produces a
reciprocal change in divergence, i.e., a change by a factor of one
half, such that the product of values for spot size and divergence
generally remains constant irrespective of the level of zoom. In
processes that depend on certain divergence thresholds, these
thresholds then constrain the spot size and vice versa.
A challenge for conventional multi-operation optical beam delivery
devices is that some processes expect a fairly tight tolerance in
terms of divergence. For instance, to inhibit laser beam 2910 from
damaging underlying tooling or foundational material, a certain
value of divergence is employed such that power begins to rapidly
diminish as laser beam 2910 propagates past its target. But if the
spot size and divergence are coupled (e.g., reciprocal), as in
conventional zoom lens systems, then an increase in spot size would
reciprocally decrease divergence and thereby concentrate power in a
manner that jeopardizes the underlying tooling surface as the spot
size is adjusted for different processes. More generally, a low
tolerance for a change in divergence could, in some processes,
constrain changes to the spatial distribution.
Likewise, where a certain tolerance of spatial distributions is
expected (e.g., to avoid under or overfilling optics), changes in
divergence could constrain changes to the spatial distribution. For
example, one application where it is advantageous to vary
divergence without a reciprocal change in spatial profile is
cutting with deposition post-processing. A laser beam at a first
divergence angle is optimized to initially pierce the metal. Then,
once the laser beam has pierced through the metal, the divergence
is changed to a second divergence angle optimizing the beam for
cutting. Another change is made to optimize the beam for deposition
during post-processing.
Beam characteristic conditioner 2964 has a capability of decoupling
spatial and angular distributions of a beam. FIG. 29 shows a change
in spatial distribution because a spot size of laser beam 2910
narrows to cut trench 2926, and this change in spatial distribution
may be achieved without a reciprocal change in angular
distribution, i.e., a non-reciprocal change. Thus, as the spot size
is narrowed, the divergence is largely maintained so that an
interior portion of plateau region 2900 is not inadvertently
damaged.
In a theoretical case, spatial and angular distributions may be
completely decoupled and therefore varied independently. In
practice, however, effects of cladding and other practical
limitations result in substantial (though not complete) decoupling.
Stated another way, the product of the values representing spatial
and angular distribution need not remain constant as parameters are
varied in response to an applied perturbation.
Having described and illustrated the general and specific
principles of examples of the presently disclosed technology, it
should be apparent that the examples may be modified in arrangement
and detail without departing from such principles. We claim all
modifications and variation coming within the spirit and scope of
the following claims.
* * * * *
References